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I ordered a drilled 1590B from PPP and the jack holes are drilled too close to the edge to use a normal Switchcraft type jack. Is there anything with a smaller profile that I can use?

Pics for reference:

Drill your jack hole out to the next size bigger. That may buy you enough room to let the jack drop lower and then sit flush. You've probably got at least one drill size up (maybe even two) with that giant washer they give you - to cover up the oversized hole.

(spoken like a true hack that has had to do this numerous times due to improper measuring)

Dan

I like to put all my I/O at the top of 1590b enclosures so keep an eye out for this kind of thing (smaller jacks), and just last week found these at farnell:

http://nz.farnell.com/lumberg/klbm-3/so ... tt=1217005

they're smaller than the long johnny ones I get at effectsconnection (which to date are the only ones I can 'just; manage to cram into that space with a DC jack). yet to try them, but they arrived yesterday and I'm particularly happy with how tiny they appear to be, and how little room they'll take up!

danielzink wrote:Drill your jack hole out to the next size bigger. That may buy you enough room to let the jack drop lower and then sit flush. You've probably got at least one drill size up (maybe even two) with that giant washer they give you - to cover up the oversized hole.

Yep. And a trip to the hardware store will probably provide you with even bigger diameter washers if need be. Grab some lockwashers while you're there, to help you secure the jacks in an offset position relative to a bigger hole. (assuming you don't already have them).

Sometimes you can find inserts at the hardware store as well. The issue with them is how long they are - if longer than the wall thickness of the box, you'll need washers to make up the difference. Again - the hardware store might have thicker washers. Just be careful not to overtighten the jack nut or you may separate it.

Yet another option would be to get JB Weld or similar, and plug the existing holes. But with that, it typically requires thin sheetmetal or similar inside the box, to reinforce your plug. The filler by itself will not be strong enough in most cases to withstand redrilling. Also be careful to keep the filler flush with the outside of the box, or you will have to sand/file it down, and risk scratching your powdercoat.

If you can get plastic nuts, that's another potential method out of the mess, since they tend to grab better and mar less than metal potentially can.